TOYOTA HIGHLANDER 2001 Service Repair Manual

A36850
Mesh Part
A53039
4545A36835
A90968
Lot No.INTAKE
EXHAUST
Engine
Front
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
58. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the threads of the plug and install it.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
59. I N S TA L L O I L C O N T R O L VA LV E F I LT E R F O R
CAMSHAFT TIMING
(a) Check that no foreign substance is on the mesh part of the
filter.
(b) Using a 6 mm socket hexagon wrench, install a new gas-
ket and the oil control valve filter with the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
60. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Install the water drain cock within the range shown in the
illustration.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
61. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface with the
Lot No. stamp upward.
NOTICE:

Remove any oil from contact surface.

Be careful of the installation direction.

To avoid damage to the gasket, place the cylinder
head on the gasket carefully.
62. INSTALL CYLINDER HEAD SUB-ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the 10 bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.

A941951 6 10 3 79 5 2 4 8
A00976
90
Engine
Front
Paint Mark
A53074
A13383
Straight
Pin
Key
Groove
A31033
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(c) Using a 10 mm bi-hexagon wrench, uniformly tighten the
10 bolts in the sequence shown in the illustration.
Torque: 79 NVm (806 kgfVcm, 58 ftVlbf)
(d) Mark the front side of each cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 in the sequence
shown in the illustration.
(f) Check that the painted marks are now at a 90 angle to
the front.
63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
64. INSTALL CAMSHAFT BEARING NO.2
(a) Install the bearing to the camshaft.
NOTICE:
Clean the contact surfaces of the bearing and the cylinder
head. the surfaces should be free of dust and oils.
65. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear and the camshaft together
with the straight pin and key groove.
(b) Turn the camshaft timing gear (as shown in the illustra-
tion) while pushing it lightly against the camshaft. Push
further at the position where the pin enters the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retarded
angle side (to the right angle).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)

A32167
A92649
12 34 5
Bearing Cap No. 1Bearing Cap No. 3
A94196
Bearing Cap No. 2
Bearing Cap No. 3
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(e) Check that the camshaft timing gear can move to the re-
tarded angle side (the right direction) and is locked at the
extreme retarded angle position.
HINT:

Apply a light coat of engine oil on the threads and under
the heads of the bolt.

Length of sprocket bolt excluding bolt head: 40 mm (1.57
in.)
66. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Fix the camshaft with a vise, and install the camshaft No.
2 timing gear.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
HINT:

Apply a light coat of engine oil on the threads and under
the heads of the bolt.

Length of sprocket bolt excluding bolt head: 25 mm (0.98
in.)
67. INSTALL CAMSHAFT BEARING NO.1
68. INSTALL CAMSHAFT (INTAKE)
(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 NVm (306 kgfVcm, 22 ftVlbf) for bearing cap No. 1
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
NOTICE:

Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 1.

Install the camshaft with its timing mark of the cam-
shaft timing gear on top.
69. INSTALL NO.2 CAMSHAFT (EXHAUST)
(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 NVm (306 kgfVcm, 22 ftVlbf) for bearing cap No. 2
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3

A32684
B11424
A94198
Timing Mark
Mark Link Timing MarkMark Link
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
NOTICE:

Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 2.

Install the camshaft with its timing mark of the cam-
shaft timing gear on top.
70. INSTALL OIL PUMP ASSY
(a) Install a new gasket and oil pump with the 3 bolts.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
71. INSTALL NO.2 CHAIN SUB-ASSY
(a) Set the crankshaft key into the left horizontal position.
(b) Turn the cutout of the drive shaft to the top.
(c) Align the mark links (yellow colored links) with the timing
marks of the sprocket as shown in the illustration.
(d) Insert the sprocket with chain to the crankshaft and oil
pump shaft.
(e) Temporarily tighten the oil pump driven sprocket with the
nut.

A90851
Chain Tensioner Plate
Bolt
Spring
Groove
A52512
90
A36525
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(f) Insert the damper spring into the adjusting hole, and
install the chain tensioner plate by the bolt.
Torque: 12 NVm (122 kgfVcm, 9.0 ftVlbf)
(g) Align the adjusting hole of the sprocket with the groove of
the oil pump.
(h) Put a bar (f 4 mm (0.16 in.)) into the adjusting hole of the
sprocket to temporarily lock the sprocket in position.
Install the nut.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
(i) Rotate the crankshaft clockwise 90, and align the crank-
shaft key with the top.
72. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
73. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

Timing Marks
Timing Marks
A53018
A52505
Mark Link
Timing Mark
A52523
SST
A13337
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74. INSTALL CHAIN SUB-ASSY
(a) Set the No. 1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gear/
sprocket and bearing caps (No. 1 and No. 2).
(2) Using the crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Align the mark link (blue or orange colored link) with the
timing mark of the crankshaft timing sprocket.
(c) Using SST, tap in the sprocket.
SST 09309-37010

Timing MarksMark Links
Timing Mark
A52513
A53064
SST
A13767
Seal
Packing
Seal Width: 2.0 mm
A90970
Seal PackingSeal Packing
Cylinder
Block Cylinder Head
Gasket
BA
AB
Seal
Packing
Cylinder
Head
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(d) Align the mark links (gold or yellow colored links) with the
timing marks of the camshaft timing gear and camshaft
timing sprocket. Then install the chain.
75. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
76. INSTALL TIMING CHAIN GUIDE
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the sensor plate with the F mark facing forward.
78. INSTALL TIMING GEAR CASE OR TIMING CHAIN
CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223-22010
(b) Apply a light coat of MP grease to the lip of the oil seal.
NOTICE:
Keep the gap between the timing chain cover edge and the
oil seal free of foreign matter.
79. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover within 3 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.0
mm (0.079 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

A
A
AAA94199
Seal Width:
3.0 to 4.0 mm 2.5 mm
(0.098 in.)
4.0 mm
(0.16 in.)
A77251
Nut
Nut
B
BB
B B BB
B
C
A
C
C
C
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(c) Apply seal packing in a continuous bead (seal width: 3.0
to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bolt A
21 NVm (214 kgfVcm, 15 ftVlbf) for bolt B
43NVm (438 kgfVcm, 32 ftVlbf) for bolt C
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for nut
(e) Install the stud bolt to the drive belt tensioner.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)

A94202
Seal PackingSeal Width:
3.0 to 4.0 mm6.0 mm
(0.236 in.)
A64641
110 911
12
13
14 8
7
6
5
432
A94203
Seal Width:
2.2 to 2.5 mm
0.5 to 1.0 mm
(0.020 to 0.039 in.)
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80. INSTALL OIL PAN SUB-ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine for at least 2 hours after instal-
ling.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the cylinder
block and oil pan.
(b) Apply seal packing in a continuous bead (seal width: 3.0
to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration,
and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
(c) Uniformly tighten the 12 bolts and 2 nuts in the sequence
shown in the illustration.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
81. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
82. INSTALL WATER PUMP ASSY
(a) Clean the contact surface of the cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.2
to 2.5 mm (0.087 to 0.098 in.)) to the outside edge of the
water pump.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the water pump within 5 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.

B12052
SST
A36335
Rib
Wire Harness
Clamp
A52071
SST
A36684
Raise
PinHook
Push
A52461
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(c) Install the water pump with the 4 bolts and 2 nuts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
NOTICE:
Tighten the outside bolts and nuts with the clamp.
83. INSTALL WATER PUMP PULLEY
(a) Using SST, install the water pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
84. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the 2 bolts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
(b) Confirm that the wire harness of the sensor is placed as
shown in the illustration.
85. INSTALL CRANKSHAFT PULLEY
(a) Install the pulley.
(b) Using SST,tighten the bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 180 NVm (1,835 kgfVcm, 133 ftVlbf)
HINT:
Apply a light coat of engine oil to the bolt threads and the area
beneath the bolt head that come in contact with the washer.
86. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger cannot spring
out.